ergo report full press

FAMU-FSU COLLEGE OF ENGINEERING

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An Ergonomic Analysis of Full Press Apparel

EIN4243: ErgonomicsNathaly ParedesEmily Singrossi

Brandon Woodall

December 3rd, 2015

Professor John Taylor

FAMU-FSU College of Engineering

2525 Pottsdamer St, Tallahassee, FL 32310

Dear Professor Taylor,

The group is submitting the attached report entitled An Ergonomic Analysis of Full Press Apparel. The start date for the project was September 10, 2015 and ends the 3rd of December 2015.

This report includes an analysis of three different tasked performed at Full Press Apparel Manufacturing Company 3445 Garber Dr, Tallahassee, FL 32303. Each of these tasks is performed in different places around the facility with different tools. Each analysis explains in depth the ergonomic problems that might be compromising the health and productivity of the workers. To better understand the problems and find feasible solutions, multiple analyses were performed. The analysis includes Seated and Standing workstation analysis (Eastman Kodak), RULA analysis, DAMES Model and BRIEF Survey. Additionally, an economic analysis will be performed after examining each of the tasks. This analysis will address financial benefits that will be of advantage for Full Press Apparel.

We would like to give a special thanks to Mr. Daniel Shrine, who was willing to help us since the beginning of this project, for taking the time to explain the team about the machines, and for letting us enter the installations while the employees were working. Additionally, the team would also like to thank the instructor Mr. Taylor since he was the one who taught us how to use the ergonomic analysis necessary in order to fulfill this project, we are sure that this will benefit all team members in our future work experience.

The group hopes this report meets all your requirements and expectations.

Sincerely yours,

Nathaly Paredes ([email protected])

Emily Singrossi ([email protected])

Brandon Woodall ([email protected])

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mailto:[email protected]

Table of Contents

1. Introduction

1.1 Purpose

1.2 Background

2. Discussion

2.1 Heat Press Machine

2.11 Description of the Task

2.1.2 Observations of the Task

2.1.3 Ergonomic Analysis

2.1.4 Evaluation of Alternatives

2.2 T-Shirt Transfer Process

2.2.1 Description of the Task




2.3 T-Shirt Folding Process





2.4 Economic Analysis and Conclusion

3. References

Appendix

Appendix 1. Worker printing a design in the Heat Press Machine

Appendix 2. Standing vs Seated Workstation for the Hand Press Machine

(Eastman Kodak)

Appendix 3. Rapid Upper Limb Assessment for the Hand Press Machine

Appendix 4. T-Shirt Folding Workstation

Appendix 5. Standing and Sitting Spine Curvature

Appendix 6. The BRIEF Survey used to show a task’s risk rating

Appendix 7. The ergonomic issues of the T-Shirt Transition process

Appendix 8. DAMES Process for T-shirt folding workstation design

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Executive Summary

An Ergonomic Analysis Report is intended to examine different tasks performed

at Full Press Apparel, which is a company located in Tallahassee, Florida. at Full

Press Apparel, a retail and production company located in Tallahassee, Florida.

Full Press Apparel has 40 workers tasked with customizing T-shirt orders through

screen printing, embroidery, and design.

The three tasks that the team will analyze include the operation of the heat press

machine, the T-shirt transfer process, and the T-shirt folding process. These

tasks are different from each other, and they are performed in different places

around the facility using different machines.

Full Press Apparel employees range over multiple demographics. One important

factor in our task analysis is that we must consider that the workstations should

be able to fit all types of populations accounting for height, gender, and several

other factors that can affect the work performed. Additionally, ergonomic tools

such as the RULA analysis, Standing Workstation Criteria Checklist, DAMES

Model, and BRIEF Survey will be performed along the report in order to find what

improvements can be made in the workplace to diminish fatigue, and increase

productivity in the workplace.

Relevant conclusions and results will be discussed along with the solutions

related to each ergonomic problem encountered. In addition, an economic

analysis is also included to determine the cost of implementing the solutions

found by the team.

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Introduction

1.1 Purpose

This projects aims to identify processes that involves a significant amount of

manual labor and determine what improvements can be made to provide a more

comfortable, safer, productive, and efficient working environment. Team

members will observe, analyze and propose solutions of several tasks by

applying the knowledge and tools acquired in their Ergonomics class. Moreover,

this analysis will assist the team in suggesting better workstation designs and

appropriate guidelines for how the work should be done in order to improve

ergonomics.

1.2 Background

Founded in 1997 by Daniel Shrine, Full Press Apparel helps meet Tallahassee’s

high collegiate demand for custom t-shirts and promotional items. Full Press

Apparel is known for transforming creative ideas into reality. It is a primary

supplier of custom screen-printing and embroidered apparel. However, through a

deep commitment to family, community service and product excellence, Daniel

has grown to serve businesses, associations, state agencies and non-profit

organizations in addition to numerous colleges and universities across the

country.

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2. Discussion

2.1 Heat Press Machine


In this task, an operator stands and folds one shirt at a time. Then the worker

places each shirt individually on the machine’s surface. The platen is then

lowered and pressed onto the machine’s surface to be printed. This task requires

pressure from the workers hand, heat from the machine, and precision work

when printing the design in the desired location. The worker will apply pressure

to the machine in 10-second intervals by repeating the same movement with their

hands and wrists for an 8-hour shift. This task image is attached in Appendix 1.

2.1.2 Observation of the task

By observing the worker perform the task, the team noticed the several

ergonomic issues that must be taken into account.

Buttons: The steaming button is too far from the workers reach. This leads to

awkward torso postures by bending and reaching to grasp the buttons.

No Job Rotation: One worker will perform the same task for 8 hours, which

engages highly repetitive motions of the wrists and hands every 10 to 15

seconds.

Repetition and Precision Required: Modify workstation to provide the option

for employees to sit, stand or lean when doing their task.

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2.1.3 Ergonomic Analysis:

A RULA analysis and a Standing vs Seated Workstation Criteria were performed.

Team members used the “Appropriate Conditions for Standing/Sit-Stand/Seated

Workstations” by Eastman Kodak to determine the appropriate workstation for

this task. According to Kodak, the workplace standing characteristics are:

frequent movements between steps are necessary, forward reach below the seat

pan, sufficient clearance, and the use of feet is not required. On the other hand,

the workplace seated position characteristics are: task requires visual attention;

the object weighs less than 10 lbs., downward forces are not required, and the

task doesn’t require handling heights above the work surface. Appendix 2 was

used to determine if the workstation dimensions are appropriate. The table height

and reaching distance from the workers location to the platen did not align with

the seated checklist. The work requires precision and a table height of 40-50”;

however, the actual height was 36”. Also, the ideal beginning working distance

and optimum work area are 1-4” and 10”x10”, respectively. The actual beginning

distance and work area are 8” and 18”x7.5”, respectively. Appendix 3 uses a

RULA analysis to evaluate the upper limb extremity ergonomic risk factors

associated with the task. By performing the RULA the team rated the task a five,

meaning further investigation is required and changes might be needed soon.


Considering both analyses performed, the team evaluated that the best

alternative is to purchase an adjustable chair for the worker to perform the task,

and to rotate between tasks since performing the same wrist movement

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repetitively might lead to Musculoskeletal Disorders. According to Eastman

Kodak Conditions, a worker should be seated when doing tasks that require

visual attention, since there’s no job rotation, the task is performed for more than

5 minutes repeatedly and that the platen weights less than 10 lbs. Moreover, if

the worker is of shorter stature, the operator won´t be able to reach the platen

leading to awkward body movements.

2.2 T-Shirt Transition Process


This process involves two machines and two operators. Two operators handle

the Automated Press Machine (APM) and part of the shirt drying oven. The APM

has eight protruding ‘shirt sized’ platforms that rotate in a circular motion via

operator command. During the rotation, a screen suspended above the platform

presses and prints on the shirts on the platform. One operator picks up a shirt to

print a design, then it is slide onto the platform of the machine through the middle

of the shirt. The shirt is now flat on a protruding platforms. The other operator is

removing a completed shirt off the protruding platform and twisting around to

properly place it on the oven behind him. The original operator, at its own

digression, commands the APM to press and rotate the shirt. The process

continues until the order is complete. The second operator also works with a

different employee to tend to the oven, this is a separate task from the T-Shirt

transition process and will not be included in the ergonomic analysis.

2.2.2 Observation of the Task

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The team observed the task for a few minutes to identify the number of T-shirts

produced. The number of T-shirts produced is equal to the number of tasks

needing ergonomic improvement, which was greater than two a minute. After

observing the task, the team identified a few possible ergonomic issues identified

in Appendix 7 below.

Back Bending: The operator bends over to flatten the shirt on the machine

each time the shirt needs preparation for the mechanical press. This process

is constant until the order is complete which, over time, effects the neck

position as well.

Wrist Rotation: When a shirt is transferred onto the machine, precision is

required to ensure the shirt is in the proper pressing position.

Back Twist and Reach: The operator transfers the shirt from the machine to

the oven directly behind them in a twisting motion. During the transfer to the

oven behind the operator, the operator must place the shirt in the proper

position on the oven. This position causes some operators to reach across

the oven to properly set the shirt.

Communication: Verbal communication is rarely used during the task

process.

Small Working Quarters: The process consists of many steps, each which

involve movement. The oven is directly behind the machine which leaves

room for a few steps rather than an entire walking motion.


To first identify the top ergonomic opportunities, the team used the BRIEF survey

method shown in Appendix 6. An operator’s neck, back and elbows had the

highest risk rating when compared to the other body parts analyzed. To eliminate

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these ergonomic risks, the team focused on what causes the back bends and

twist, elbow extension and neck bends. After speaking to the operators, the team

identified the first operator’s task as precision work. The shirt needed to be

specifically placed to ensure the image printed was properly aligned with the shirt

center and pocket. This means the APM workstation needs to stand at 40

inches, according to the North American male minimum workstation height

requirement. However, the APM inadequately stands at 37 inches, which causes

the risky back/neck bends and full elbow extension. The operator hunches over

to align the T-shirt, bending his back and neck over 20 degrees. The increase in

angle forces his elbows to fully extend their 135 degrees.

The T-shirt transition process expects the operators to move freely amongst one

another when completing tasks. A second operator has an issue moving freely

and cannot access the proper T-shirt placement on the oven rack. When the first

operator is bent over he takes up more space than when he stands straight.

Operator two, then, twists to place the T-shirt in the smaller workspace. A larger

workspace area would eliminate an operator’s need to twist his back.

2.2.4 Evaluation of Alternatives and Solution Development

Based on Eastman Kodak the team determined a set of possible solution based

on the seated/standing workstations and machine alteration justification. An

operator performing precision work is typically best preformed seated; however,

the job workplace characteristics require an operator to stand. In the T-Shirt

transition process, a downward force above 10 pounds is required to imprint the

screen on the T-shirt, frequent forward reaches above 14.8” are required when

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pulling down the screen, and frequent movement between workstations is

required. These outweigh the suggested seated condition for precision work.

Justification of the operator standing helps validate the need to raise and move

the machine. The team recommends to raise the APM to 50 inches and move it

two feet away from the oven. This raise is based off North American standards,

the maximum value for all demographics. In order to ensure all operators can

reach the machine, the team recommends having a portable step stool near the

APM.

2.3 T-Shirt Folding Process


The T-shirt folding process uses a standing workstation that is typically occupied

by one to two workers based on the amount of T-shirts produced during that shift.

At this station, the shirts are exiting the oven from the T-shirt transition process

on a conveyor belt. The shirts are then picked up off the conveyor and moved to

one of two tables that are positioned perpendicular to the end of the conveyor

belt; however, if a shirt is not grabbed off the conveyor in time, the shirt is

dumped into a bin that is placed on the ground beneath it. The two tables are

located were the shirts are folded then placed into their respective piles based on

the shirts size and style. From there the piles of shirts are placed into boxes

where they are then prepped for shipping. An illustration of this workstation can

be seen in Appendix 4.

2.3.2 Observation of the Task

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After analyzing the two employees work in this process for several minutes, there

were a few observations made that can affect the ergonomic efficiency of the

workstation, which can be seen in Appendix 4 and are bulleted below.

Seated or Standing Workstation: The current work area requires the

employees to stand throughout their shift, however the workstation is large

enough to support one or two mobile chairs for the employees to work from.

Shirt Bin Placed on the Floor: Shirts not removed from the conveyor in time

are dropped into a collection bin that is placed on the floor. Continuously

bending over to pick up these shirts from the bin can cause excessive stress

on the employee’s backs.

Light Work: The process of grabbing the shirts, folding and placing them into

a pile is considered light work and does not constitute as precision.

Height of Employees Varies Drastically: Two employees working in the folding

area varied in height by over 10 inches. This must be accounted for designing

workstation that has to accommodate both the shorter and taller employees.


For this task the DAMES process was used to perform a workstation design

analysis, this process is illustrated in Appendix 8. The primary focus was to

decide whether or not to make a standing or seated workstation. Standing for

long periods of time curves the lower back forward, a condition called Lordosis.

Sitting down curves the back in the other direction, a condition called Kyphosis.

These two conditions can be seen in Appendix 5.

Again, the goal is to reduce stress on the back, therefore recommendations for

both seated and standing workstations were made to decide which is more

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ergonomically safe. Since the work is classified as “light work,” the recommended

table height should range from 35.2” to 44.9” for a standing workstation to

accommodate both small females and large males in North America, according

to the Ergonomic Design Guidelines for Engineers. For a seated workstation the

recommended table height is 21” to 34”. It is also recommended that work be

done from 1” to 14” from the edge of the table to avoid excessive leaning and

bending of the back. Purchasing an adjustable table that can rise or sink to the

height range is recommended for this workstation. Lastly, it is recommended that

the height of the collection bin be raised to a minimum height of 24” off the

ground to reduce the amount of bending over to retrieve the shirts out of it.


All the recommendations made for the workstation design are efficient in making

the work safe from an ergonomic standpoint; however, since the work requires a

lot of travel between tables, conveyor belt, bin etc. and the does not require

precision, a standing workstation is more ideal for this process. Along with being

a standing workstation, the use of an adjustable table between the heights of

35.2” and 44.9” is strongly recommended since there is such a large difference in

heights of the employees. The final design recommendation is to place blocks or

a platform beneath the collection bin to a minimum height of 24” to reduce the

stress of back bending to lower heights

2.4 Economic Analysis and Conclusion

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According to the analysis performed at Full Press Apparel the team concluded

different recommended solutions for:

Task 1: The components that will be needed are an adjustable chair and to rotate

job between workers. Selecting an adjustable office chair costs ranges from

$169.00 to $450.00 (“Chairs & Seating at Office Depot and OfficeMax”). Full

Press Apparel has 40 employees, it would be optimal to select one of those

workers and rotate between tasks.

Task 2: Full Press Apparel will need to budget for moving the machine. This cost

will be neglected because one less operator will need to complete this task.

Assuming salary is minimally $31,200 a year, Full Press will benefit from a

tradeoff of contracting the manufacturer at less than the operator’s annual salary.

Task 3: The components that will be needed are an adjustable table based on

results. Adjustable tables range from $479 to $1449 based on the sizes and

quality of the tables (“Adjustable Tables Office Depot and Office Max”)

Usually the direct cost per year per individual patient with musculoskeletal

disorders has increased nearly 61% between the years 2009 to 2011, rising from

just over $4,800 to nearly $7,800 per person (Yelin). For shifts with a large

product demand, fatigue can set in quickly with the repetitive motions of

grabbing, reaching, bending, folding and placing the shirts. Long term effects of

continuous strain on the back caused from poor posture can lead to severe spine

disorders such as Lordosis, Kyphosis and Scoliosis. Therefore, the total cost for

implementing these solutions will be less expensive than handling a medical bill.

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References

“Adjustable Tables Office Depot and Office Max”. Adjustable Tables at

Office Depot and Office Max. N.p..n.d. Web 27 Nov. 2015.

"Chairs & Seating at Office Depot and Office Max." Chairs & Seating at

Office Depot and Office Max. N.p., n.d. Web. 27 Nov. 2015.

“Workstation Heights and Distances” Ergonomic Design Guidelines for

Engineers. N.p., n.d. Web. 1 Dec. 2015.

Yelin, Edward. "Chairs & Seating at Office Depot and OfficeMax." Chairs

& Seating at Office Depot and OfficeMax. N.p., n.d. Web. 27 Nov. 2015.

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Appendix

Appendix 1 : Worker printing a design in the Heat Press Machine

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Appendix 2. Standing vs Seated Workstation for the Hand Press Machine

(Eastman Kodak)

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Appendix 3. Rapid Upper Limb Assessment for the Hand Press Machine

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Appendix 4: T-Shirt Folding Workstation

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Appendix 5. Standing and Sitting Spine Curvature

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Appendix 6. The BRIEF Survey used to show the highest risk rating, two, during the T-Shirt transition task

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Appendix 7. The ergonomic issues of the T-Shirt Transition process

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Appendix 8. DAMES Process for T-shirt folding workstation design

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